Methods and apparatus for cutting profiles

ABSTRACT

An apparatus for cutting a profile, including: a cutter configured to make cuts on the profile having a first surface and a second surface, and having at least one rib on the first surface, wherein the cuts are made on the first surface of the profile; a first drive unit to drive the cutter forward and backward to and from the first surface of the profile; and a second drive unit to drive the cutter up and down along the first surface of the profile.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of Korean PatentApplication No. 10-2007-112810, filed Nov. 6, 2007. The disclosure ofthe above-referenced patent application is incorporated herein byreference.

BACKGROUND

1. Field of the Invention

The present invention relates to methods and apparatus for cuttingprofiles.

2. Background

FIG. 1 shows a conventional machine 1 for folding a metal strip or rule10 of a flat type into a predetermined shape. The structure andoperation of a typical conventional machine is described in KoreanPatent Registration No. 10-0233335, filed Nov. 20, 1996; and KoreanPatent Registration No. 10-388889, filed Apr. 3, 1999. However, theconventional folding machine 1 shown in FIG. 1 can be used mostly forfolding flat strip or rule. Thus, to fold a strip or rule of othershapes, a new design is desirable.

SUMMARY

Certain embodiments as disclosed herein provide methods, apparatus, andcomputer programs for cutting profiles. In some embodiments, methods,apparatus, and computer programs described herein provide for cuttingand folding profiles to make channel letters for a sign board.

In one aspect, an apparatus for cutting a profile is disclosed. Theapparatus including: a cutter configured to make cuts on the profilehaving a first surface and a second surface, and having at least one ribon the first surface, wherein the cuts are made on the first surface ofthe profile; a first drive unit to drive the cutter forward and backwardto and from the first surface of the profile; and a second drive unit todrive the cutter up and down along the first surface of the profile.

In another aspect, a folding machine for cutting and folding profiles tomake channel letters for a sign board is disclosed. The folding machineincluding: a profile supply unit configured to feed a profile into thefolding machine; a profile feeding path coupled to the profile supplyunit, and configured to guide the profile for cutting; a cutting unitcoupled to the profile feeding path, the cutting unit comprising: acutter configured to make cuts on the profile having a first surface anda second surface, and having at least one rib on the first surface,wherein the cuts are made on the first surface of the profile; a firstdrive unit to drive the cutter forward and backward to and from thefirst surface of the profile; a second drive unit to drive the cutter upand down along the first surface of the profile; a folding unitconfigured to fold the profile that is properly cut into a channelletter.

In another aspect, a method for cutting a profile is disclosed. Themethod including: determining a cut depth of a cut to be made with acutter on the profile; appropriately selecting and engaging a stopper toallow the cutter to receive and cut the profile; first moving the cutterforward for first cutting and/or backward for repositioning; secondmoving the cutter down and/or up for second cutting or repositioning;repeating first moving and second moving according to a desired numberof cuts.

In yet another aspect, a computer-readable storage medium storing acomputer program for cutting a profile is disclosed. The computer theprogram including executable instructions that cause a computer to:determine a cut depth of a cut to be made with a cutter on the profile;appropriately select and engage a stopper to allow the cutter to receiveand cut the profile; first move the cutter forward for first cuttingand/or backward for repositioning; second move the cutter down and/or upfor second cutting or repositioning; repeat the first move and thesecond move according to a desired number of cuts.

Other features and advantages of the present invention will become morereadily apparent to those of ordinary skill in the art after reviewingthe following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of the present invention, both as to its structure andoperation, may be gleaned in part by study of the accompanying drawings.

FIG. 1 is a perspective view illustrating a conventional foldingmachine;

FIG. 2 illustrates a profile including protruding ribs;

FIG. 3 illustrates a folding machine including a profile supply unit, aprofile feeding path, a cutting unit, and a profile folding unit inaccordance with one embodiment of the present invention;

FIG. 4 shows the profile with a portion (see Part B) of protruding ribscut in a predetermined shape on both sides of the folding line (see LineA);

FIG. 4A shows Part B of FIG. 4 in more detail;

FIG. 5 shows one example of a desired fold shape of the profile afterbeing cut in the cutting process described with respect to FIG. 4 andFIG. 4A, and folded along Line A for angle C;

FIG. 6 shows an exploded view of the cutting unit in accordance with oneembodiment of the present invention;

FIG. 7 shows a perspective view of the cutting unit with a cutter in anengaged position;

FIG. 8 shows another perspective view of the cutting unit with a coverover the cutter and a profile in position for cutting;

FIG. 9 shows the cutting unit prior to engaging the profile for cutting;

FIG. 9A shows thin front end of a stopper positioned between a securingwheel and a support member;

FIG. 9B shows thick rear end of a stopper positioned between a securingwheel and a support member;

FIG. 10 shows the cutting unit in an engaged position for cutting theprofile;

FIG. 11 shows the cutting unit in another engaged position for cuttingthe profile, wherein the profile is moved at a predetermined interval;and

FIG. 12 is a flowchart illustrating a process of cutting the profile inaccordance with one embodiment of the present invention.

DETAILED DESCRIPTION

Certain embodiments as disclosed herein provide methods and apparatusfor cutting profiles. In some embodiments, methods and apparatusdescribed herein provide for cutting and folding profiles to makechannel letters for a sign board. References will be made in detail tothese embodiments including examples illustrated in the accompanyingdrawings. Technical structure and operation of the device will bedescribed with reference to the drawings in FIGS. 2 through 11.

As described above, conventional folding machines have structuraldifficulties in folding metal rules (or strips) of shapes that are notflat. For example, the conventional folding machine shown in FIG. 1would have difficulty folding metal rule 110 that has protruding ribs ortabs 110 a and 110 b, which protrude out of one side of the metal ruleat top and bottom ends, as shown in FIG. 2, for example.

In some embodiments, the metal rule (or other rigid material) of theshape illustrated in FIG. 2 can be used to make channel letters for signboards. In sign board applications, the material that is used to makechannel letters, as shown in FIG. 2, is sometimes referred to as“profile”. Further, the profile is usually made of metallic material butcan be made of aluminum, other rigid/semi-rigid material, or combinationof both. Accordingly, the term “profile” is used throughout thisdisclosure to mean board or strip having ribs or tabs, and is made ofmetallic and/or other rigid/semi-rigid material.

In one embodiment, the protruding rib 110 b that protrudes out at thebottom end is used to insert or place a front panel once the metal rule110 has been folded into a desired shape or letter. The protruding rib110 a that protrudes out at the top end can be used to insert or place aback panel once the metal rule 110 has been folded into a desired shapeor letter.

FIG. 3 illustrates a folding machine 2 including a profile supply unit90, a profile feeding path 30, a cutting unit 20, and a profile foldingunit 101 in accordance with one embodiment of the present invention. Thecutting unit 20 is provided near the profile feeding path 30 to cut aportion of the protruding ribs 110 a and 110 b in an angle to facilitatefolding of the profile. The folding machine 2 of FIG. 3 is configured tofold the profile having protruding ribs 110 a and 110 b protruding outof one side of the metal rule at top and bottom ends, as shown in FIG.2.

To describe the cutting and folding process in detail, FIG. 4, forexample, shows a profile 110 having protruding ribs 110 a and 110 b.This profile 110 is fed into the folding machine 2 through a profilesupply unit 90, and is transferred through the profile feeding path 30in the direction shown in FIG. 3. While the profile 110 is beingtransferred through the profile feeding path 30, a portion of theprotruding ribs 110 a and 110 b is cut in an angle by the cutting unit20 to facilitate the folding of the profile 110. Once the profile 110 isproperly cut by the cutting unit 20, the profile folding unit 101 foldsthe cut profile 110.

FIG. 4 shows the portion (see Part B) of the protruding ribs 110 a and110 b cut in a predetermined shape on both sides of the folding line(see Line A). Thus, in the illustrated embodiment of FIG. 4, inanticipation of the profile 110 being folded along Line A, the cuttingunit 20 provides two “V” cuts on each side of Line A and one “V” cutcentered at Line A, for a total of five “V” cuts. Although cuts in thisembodiment are described as five “V” cuts, any shape and/or any numberof cuts can be made on the ribs to facilitate the folding process. Forexample, five “V” cuts can provide easy folding of the profile 110 intoapproximately 300-degree angle (see angle C in FIG. 5). However, less ormore number of cuts can provide easy folding of the profile 110 intoangles less than or greater than 300 degrees. Further, the cut shape canbe made in “U” shape or any other appropriate shape rather than a “V”shape. In other embodiments, the size of the V cut can be controlled todetermine the angle of the fold.

To further describe the cutting process in detail, the cutting portion(Part B) of the profile 110 is shown in detail in FIG. 4A. In theillustrated embodiment of FIG. 4A, when it is desired to fold theprofile 110 along Line A, two cuts 112 are made on the left side of LineA. Another cut 114 is made centered at Line A. Then, two more cuts 116are made on the right side of Line A, as shown. In some embodiments,scratch lines or cut lines 118 are made along the center of the cuts112, 114, 116 to further facilitate the folding of the profile 110. Thescratch lines 118 are made carefully on the same side of the profile asthe protruding ribs 110 a and 110 b so that profile 110 can be foldedalong those lines without cutting the profile 110 at those lines. Seenin detail in FIG. 4A, the scratch lines 118 make tiny ridges on thesurface of the profile 110. In one example, the depth of the ridges madeby the scratch lines 118 is approximately one-third of the thickness ofthe profile. This leaves approximately two-thirds of the thickness ofthe profile for easier folding with completely cutting the profile.Further, in the illustrated embodiment of FIG. 4A, the V cuts are madeon both ribs 110 a and 110 b so that the tip of the V shape cuts fromthe open edge 150 all the way to the closed edge 120 of the ribs 110 aand 110 b, and can penetrate slightly further into the profile to matchwith the tiny ridges made by the scratch lines 118. Generally, the cutsmade on the rib are angled so that the open edge 150 has a larger anglethan the closed edge 120.

FIG. 5 shows one example of the desired fold shape of the profile 110after being cut in the cutting process described above with respect toFIG. 4 and FIG. 4A, and folded along Line A for angle C. Thus, theillustrated embodiment of FIG. 5 shows that the profile 110 can beeasily folded into a desired angle because of the cuts made in the ribs110 a and 110 b and the surface of the profile 110. Thus, it can be seenthat by making different angle cuts on the ribs 110 a and 110 b and thescratch lines 118 on the surface 140 of the profile 110, any shape ofchannel letters can be easily produced using profiles.

FIG. 6 shows an exploded view of the cutting unit 20 in accordance withone embodiment of the present invention. FIG. 7 shows a perspective viewof the cutting unit 20 with a cutter 70 in an engaged position. FIG. 8shows another perspective view of the cutting unit 20 with a cover 79over the cutter 70 and a profile 110 in position for cutting.

In the illustrated embodiment of FIG. 6 through FIG. 8, the cutting unit20 includes a frame 60 coupled to the profile feeding path 30, whereinthe frame 60 and the profile feeding path 30 form a slit 200 throughwhich a profile with protruding ribs can be fed. The cutting unit 20also includes a fixing plate 50 which forms a plate for attaching otherparts of the cutting unit 20. Also, a bottom plate 63 is fixed to thebottom end of the fixing plate 50. The frame 60 is provided with anopening 61 to allow a cutter 70 to move forward and backward (along Zaxis) through the opening 61 to make cuts (similar to cuts 112, 114,116) in the ribs 110 a and 110 b of a profile 110. The shape of theopening 61 also allows the cutter 70 to move up and down (along Y axis)to make scratch lines (similar to scratch lines 118). However, it isunderstood that the cutter movement forward and backward along Z axiscan provide cuts in the ribs or make scratch line, and that the cuttermovement up and down along Y axis can also provide cuts in the ribs ormake scratch lines. In the illustrated embodiment of FIG. 6 through FIG.8, the shape of the cutter 70 is configured so that it makes a V-shapecut in the ribs. However, cutters of other shapes can be configured tocut other shapes such as a U-shape cut.

In the illustrated embodiment of FIG. 6 through FIG. 8, a Y-axis sliderail 41 is provided on the fixing plate 50 along the Y-axis direction,and a moving plate 40 is attached to the Y-axis slide rail 41, whichmoves the moving plate 40 up and down along Y-axis. A screw drivingmotor 80 is coupled to the moving plate 40 to drive a vertical axisscrew 81 which is threaded into the moving plate 40. Thus, the verticalaxis screw 81 is rotated by the driving motor 80 in a direction parallelto the Y-axis slide rail 41. The lower end of the vertical axis screw 81is configured to rest on top of the bottom plate 63. Since the screwdriving motor 80 and the vertical axis screw 81 are coupled to themoving plate 40, as described above, the screw driving motor 80 drivesthe moving plate 40 up and down along the Y-axis direction parallel tothe Y-axis slide rail 41.

The cutting unit 20 also includes a cutter driving motor 75, a Z-axisslide rail 42, a first cylinder 55, a support member 95, abi-directional rod 56, a securing wheel 59, a stopper 72, and a secondcylinder 77. The cutter driving motor 75 drives the cutter 70, and isfixed to the sidewall of the moving plate 40 using the Z-axis slide rail42. Thus, the Z-axis slide rail 42 allows the first cylinder 55 to drivethe cutter driving motor 75 forward and backward along the Z-axisdirection. The first cylinder 55 is coupled to the support member 95,which is in turn coupled to one side of the moving plate 40. The firstcylinder 55 drives the bi-directional rod 56 through its opening to movethe cutter driving motor 75 along the Z-axis direction. The rod 56includes an inner rod 56 a and an outer rod 56 b, which are formed as asingle body. The inner rod 56 a is coupled to the cutter driving motor75, while the outer rod 56 b passes through the support member 95 and iscoupled to the securing wheel 59. The stopper 72 is designed to providea multi-level depth control in such a way that the movement of thecutter driving motor 75 along the Z-axis direction can be controlled. Inthe illustrated embodiment of FIG. 6 through FIG. 8, the stopper 72 isdesigned for only two depth levels between the securing wheel 59 and thesupport member 95. The stopper 72 is connected to a rod of the secondcylinder 77, and is fixed to one side of the support member 95.

In the illustrated embodiment of FIG. 6 through FIG. 8, the cutter 70 isalso coupled to the cutter driving motor 75 through a cutter axis rod73. The cutter 70 is configured to be driven by the cutter driving motor75 which rotates the cutter 70 using the cutter axis rod 73. A cover 79partially covers the cutter 73, wherein uncovered side of the cutter 73is configured to face the profile 110 through the opening 61 for cuttingthe profile. The cover 79 is fixed to the body 74 of the cutter drivingmotor 75.

Elements of the cutting unit 20 described in FIG. 6 through FIG. 8 canbe assigned as follows in a general description: a cutting apparatus 20for cutting a profile, including: a cutter 70 configured to make cuts onthe profile 110, wherein the profile 110 has a first surface 140 and asecond surface, the profile 110 has at least one rib 110 a and 110 b onthe first surface 140, and the cuts are made on the first surface 140; afirst drive unit 55, 56, 42, 59, 77, 72 to drive the cutter 70 forwardand backward to and from the first surface 140 of the profile 110; and asecond drive unit 80, 81, 40, 41 to drive the cutter 70 up and down onthe first surface 140 of the profile 110.

FIG. 9 through FIG. 11 illustrate a process of cutting the profile inaccordance with one embodiment of the present invention. FIG. 9 showsthe cutting unit 20 prior to engaging the profile for cutting. FIG. 10shows the cutting unit 20 in an engaged position for cutting the profile110. FIG. 11 shows the cutting unit 20 in another engaged position forcutting the profile 110, wherein the profile 110 is moved at apredetermined interval.

At the initial stage of the cutting process (as shown in FIG. 9), thedepth of a cut to be made on the ribs of the profiles is determined.Once the cutting depth is determined, the distance by which the cutterdriving motor 75, and hence the cutter 70, is to be moved forward in theZ-axis direction can be set by the positioning of the stopper 72 betweenthe securing wheel 59 and the support member 95. For example, if thecutting depth to be made on the profile 110 is set as a deep cut, then asecond cylinder 77 is driven so that a thin front end 72 a of thestopper 72 is positioned between the securing wheel 59 and the supportmember 95 (see FIG. 9A) so that the cutter 70 can be moved forwarddeeply into the profile along the Z-axis direction. However, if thecutting depth to be made on the profile 110 is set as a shallow cut,then a second cylinder 77 is driven so that a thick rear end 72 b of thestopper 72 is positioned between the securing wheel 59 and the supportmember 95 (see FIG. 9B) so that the cutter 70 can be moved forward lessthan when the thin front end 72 a is used. When moving the stopper 72between positions shown in FIG. 9A and FIG. 9B, the second cylinder 77should be driven only during a state where the cylinder rod 56 connectedto the cutter driving motor 75 is moved in a direction opposite theZ-axis direction (i.e., the negative-Z direction) so that there isenough space along the cylinder rod 56 between the securing wheel 59 andthe support member 95 for the stopper 72 to be moved in.

Once the cutting depth has been determined and an appropriate stopper 72has been selected and engaged, the profile 110 is then fed through theslit 200 until Line A (see FIG. 4) reaches a predetermined point nearthe opening 61, as shown in FIG. 10. Once the profile 110 has reachedand come to a rest at an initial cutting position, the first cylinder 55is driven to push the rod 56 toward the profile feeding path 30, therebymoving the cutter driving motor 75 and, in turn, the cutter 70 forwardin the Z-axis direction. The cutter 70 is then rotated and moved throughthe opening 61 to cut into the profile 110 for a predetermined cuttingdepth. If the cutter 70 is initially positioned at the top end of theprofile 110 to make a cut at the top of the profile 110, then the screwdriving motor 80 can now drive the moving plate 40 down along the Y-axisdirection to move the cutter 70 down with it to make the scratch line118 on the inside surface 140 of the profile 110 and the V cuts in thetop rib 110 a and the bottom rib 110 b of the profile 110. When a cutalong the first line (along the Y-axis direction) is completed, thecutter 70 returns to its original position as illustrated in FIG. 9. Theprofile 110 is moved at a predetermined interval as illustrated in FIG.11.

In an alternative embodiment, the cutter 70 is initially positioned atthe bottom end of the profile 110 to make a cut at the bottom of theprofile 110, then the screw driving motor 80 now drives the moving plate40 up along the Y-axis direction to move the cutter 70 up with it tomake the scratch line 118 on the inside surface 140 of the profile 110and the V cuts in the bottom rib 110 b and the top rib 110 a of theprofile 110. Other embodiments with different orders for theabove-described steps are also contemplated.

The above-described process can be summarized generally as follows:determining a cut depth of a cut to be made with a cutter on theprofile; appropriately selecting and engaging a stopper to allow thecutter to cut the profile; receiving the profile for cutting; firstmoving the cutter forward for first cutting and/or backward forrepositioning; second moving the cutter down and/or up for secondcutting or repositioning; and repeating first moving and second movingaccording to a desired number of cuts.

FIG. 12 is a flowchart illustrating a process of cutting the profile inaccordance with one embodiment of the present invention. At the initialstage of the cutting process, the depth of a cut to be made on the ribsof the profiles is determined (see Box 1202). Once the cutting depth isdetermined, the distance by which the cutter driving motor 75, and hencethe cutter 70, is to be moved forward in the Z-axis direction can be setby the positioning of the stopper 72 between the securing wheel 59 andthe support member 95, at Box 1204. Once the cutting depth has beendetermined and an appropriate stopper 72 has been selected and engaged,the profile 110 is then fed through the slit 200, at Box 1206, untilLine A reaches a predetermined point near the opening 61.

Once the profile 110 has reached and come to a rest at an initialcutting position, the first cylinder 55 is driven to push the rod 56toward the profile feeding path 30, thereby moving the cutter drivingmotor 75 and, in turn, the cutter 70 forward in the Z-axis direction, atBox 1208. The cutter 70 is then rotated and moved through the opening 61to cut into the profile 110 for a predetermined cutting depth.

The foregoing embodiments are merely presented as examples and are notto be construed as limiting the present invention. The present teachingscan be readily applied to other types of methods, apparatus and/ordevices. In other embodiments, the teachings embodied in the method(s)can also be implemented as computer programs stored in storage medium.The description of the present invention is intended to be illustrative,and not to limit the scope of the claims. Many alternatives,modifications, and variations will be apparent to those skilled in theart.

What is claimed is:
 1. An apparatus for cutting a profile, comprising: acutter configured to make cuts on the profile having a first surface anda second surface, and having at least one rib on the first surface,wherein the cuts are made on the first surface of the profile; a firstdrive unit to drive said cutter forward and backward to and from thefirst surface of the profile; and a second drive unit to drive saidcutter up and down along the first surface of the profile.
 2. Theapparatus of claim 1, further comprising a cutter driving motorconfigured to rotate said cutter for cutting the profile.
 3. Theapparatus of claim 2, wherein said first drive unit comprises: abi-directional rod coupled to said cutter driving motor; a first sliderail coupled to said cutter driving motor; a cylinder configured todrive said bi-directional rod, wherein the driving of saidbi-directional rod moves said cutter driving motor on said first sliderail forward to and backward from the first surface of the profile. 4.The apparatus of claim 3, wherein said first drive unit furthercomprises: a stopper; and a securing wheel, wherein said stopper andsaid securing wheel operates together to limit the movement of saidbi-directional rod to control the depth of a cut made by said cutter onthe first surface of the profile.
 5. The apparatus of claim 2, whereinsaid second drive unit comprises: a moving plate coupled to said cutterdriving motor; a second slide rail coupled to said moving plate; adriving motor configured to drive said moving plate on said second sliderail, wherein the driving of said moving plate moves said cutter drivingmotor and said cutter up and down along the first surface of theprofile.
 6. The apparatus of claim 5, further comprising a vertical axisscrew coupled to said driving motor and said moving plate, wherein saidvertical axis screw is driven by said driving motor to move said movingplate vertically on said second slide rail.
 7. The apparatus of claim 1,wherein the cuts made on the at least one rib are angled so that an openedge of the at least one rib has a larger angle than a closed edge. 8.The apparatus of claim 1, wherein the cuts made on the surface of theprofile produce a small ridge with a depth equal to approximatelyone-third the thickness of the profile.
 9. A folding machine for cuttingand folding profiles to make channel letters for a sign board,comprising: a profile supply unit configured to feed a profile into thefolding machine; a profile feeding path coupled to said profile supplyunit, and configured to guide said profile for cutting; a cutting unitcoupled to said profile feeding path, said cutting unit comprising: acutter configured to make cuts on the profile having a first surface anda second surface, and having at least one rib on the first surface,wherein the cuts are made on the first surface of the profile; a firstdrive unit to drive said cutter forward and backward to and from thefirst surface of the profile; a second drive unit to drive said cutterup and down along the first surface of the profile; a folding unitconfigured to fold said profile that is properly cut into a channelletter.
 10. The folding machine of claim 9, wherein said cutting unitcomprises a frame coupled to said profile feeding path, said framedisposed parallel to said profile feeding path, and together forming aslit through which the profile is fed through for cutting.
 11. A methodfor cutting a profile, comprising: determining a cut depth of a cut tobe made with a cutter on the profile; appropriately selecting andengaging a stopper to allow the cutter to receive and cut the profile;first moving the cutter forward for first cutting and/or backward forrepositioning; second moving the cutter down and/or up for secondcutting or repositioning; repeating said first moving and said secondmoving according to a desired number of cuts.
 12. The method of claim11, further comprising positioning the cutter initially at a top end ofthe profile, wherein said first moving includes moving the cutterforward for the first cutting, said second moving includes moving thecutter down for the second cutting, said repeating includes first movingthe cutter backward for repositioning, and second moving the cutter upfor repositioning.
 13. The method of claim 11, further comprisingpositioning the cutter initially at a bottom end of the profile, whereinsaid first moving includes moving the cutter forward for the firstcutting, said second moving includes moving the cutter up for the secondcutting, and said repeating includes first moving the cutter backwardfor repositioning.
 14. A computer-readable storage medium storing acomputer program for cutting a profile, the program comprisingexecutable instructions that cause a computer to: determine a cut depthof a cut to be made with a cutter on the profile; appropriately selectand engage a stopper to allow the cutter to receive and cut the profile;first move the cutter forward for first cutting and/or backward forrepositioning; second move the cutter down and/or up for second cuttingor repositioning; repeat said first moving and said second movingaccording to a desired number of cuts.